A study on machining performance of wire electric discharge grinding (WEDG) process during machining of tungsten alloy micro-tools

In this experimental study, tungsten alloy micro-tools of high aspect ratio are machined through wire electric discharge grinding (WEDG) method using the step machining technique on a hybrid micro-electro-discharge machine to achieve high productivity and finish. Tungsten alloy micro-tools are widely used in the fabrication of miniature products. The precise and economical machining of the tungsten material with an optimum level of accuracy and surface properties is a challenge because of its exceptional characteristics like hot hardness, high strength, low wear, and corrosion rate. The material removal rate (MRR) and surface roughness (Ra) responses are studied during machining of micro-tools, selecting the variability of applied voltage, circuit capacitance, and spindle speed during machining for a constant-aspect-ratio micro-tool. Both voltage and capacitance are found to be influencing parameters for MRR and surface roughness. Higher voltage and capacitance values tend to increase MRR and roughness values on the machined micro-tool. Further, the parametric conditions are also identified for higher MRRs and lower surface roughness (Ra) values after employing the hybrid Taguchi design of experimentation methodology. Surface topography of the machined surface studied by energy-dispersive spectroscopy (EDS) reveals the presence of pyrolytic carbon and oxygen elements. Field emission scanning electron microscopy (FESEM) images show a little waviness across the machined surface. A mathematical model is developed to evaluate the correlation among governing parameters for machining response and validated by confirmation experiments. The machining procedure can be further developed to fabricate more predominant fluted micro-tools for difficult-to-machine tungsten material.